Carrier 61WG 020 Manual

INSTALLATION, OPERATION AND
MAINTENANCE INSTRUCTIONS
Water-Cooled/Condenserless
Liquid Chillers/Water-Sourced Heat Pumps
with or without Integrated Hydronic Module
61WG/30WG/30GA 020-090
Original document
Nominal cooling capacity 25-95 kW
Nominal heating capacity 29-117 kW
Unit with optional hydronic module Standard unit
PRO-DIALOG

2
CONTENTS
1 - INTRODUCTION ..................................................................................................................................................................... 5
1.1 - Installation safety considerations ........................................................................................................................................... 5
1.2 - Equipment and components under pressure......................................................................................................................... 6
1.3 - Maintenance safety considerations......................................................................................................................................... 6
1.4 - Repair safety considerations ................................................................................................................................................... 7
1.5 - Measures, provisions, procedures against emergencies ........................................................................................................ 9
2 - PRELIMINARY CHECKS ...................................................................................................................................................... 9
2.1 - Check equipment received...................................................................................................................................................... 9
2.2 - Moving and placing the unit....................................................................................................................................................9
3 - DIMENSIONS, CLEARANCES........................................................................................................................................... 11
3.1 - 61WG/30WG 020-045 - standard unit.................................................................................................................................. 11
3.2 - 61WG/30WG 020-045 - unit with top connections (option 274)....................................................................................... 11
3.3 - 61WG/30WG 020-045 - unit with evaporator hydronic module (option 116)................................................................. 12
3.4 - 61WG/30WG 020-045 - unit with condenser hydronic module (option 270).................................................................. 12
3.5 - 61WG/30WG 020-045 - unit with evaporator/condenser hydronic modules (options 116 + 270) ................................ 12
3.6 - 61WG/30WG 020-045 - unit with hydronic module and top connections (options 116 + 274 or 270 + 274 or 116 +
270 + 274) ................................................................................................................................................................................ 13
3.7 - 61WG/30WG 020-045 - stackable unit (option 273) .......................................................................................................... 13
3.8 - 61WG/30WG 050-090 - standard unit.................................................................................................................................. 14
3.9 - 61WG/30WG 050-090 - unit with top connections (option 274)....................................................................................... 14
3.10 - 61WG/30WG 050-090 - unit with evaporator hydronic module (option 116)............................................................... 15
3.11 - 61WG/30WG 050-090 - unit with condenser hydronic module (option 270)................................................................ 15
3.12 - 61WG/30WG 050-090 - unit with evaporator/condenser hydronic modules (options 116 + 270) .............................. 15
3.13 - 61WG/30WG 050-090 - unit with hydronic module and top connections (options 116 + 274 or 270 + 274 - 116 or
270 + 274) .............................................................................................................................................................................. 16
3.14 - 61WG/30WG 050-090 - stackable unit (option 273) ........................................................................................................ 16
3.15 - 30WGA 020-045 - standard unit ......................................................................................................................................... 17
3.16 - 30WGA 020-045 - unit with evaporator hydronic module (option 116)........................................................................ 17
3.17 - 30WGA 020-045 - stackable unit (option 273).................................................................................................................. 18
3.18 - 30WGA 050-090 - standard unit ......................................................................................................................................... 18
3.19 - 30WGA 050-090 - unit with evaporator hydronic module (option 116)........................................................................ 19
3.20 - 30WGA 050-090 - stackable unit (option 273) ................................................................................................................. 19
4 - PHYSICAL AND ELECTRICAL DATA 61WG/30WG................................................................................................... 20
4.1 - Physical data 61WG ............................................................................................................................................................... 20
4.2 - Physical data 30WG ............................................................................................................................................................... 20
4.3 - Physical data 30WGA............................................................................................................................................................ 21
4.4 - Physical data 61WG/30WG/30WGA units with hydronic module .................................................................................. 21
4.5 - Electrical data 61WG/30WG/30WGA ................................................................................................................................ 22
4.6 - Short-circuit stability current (TN system*) - standard unit (with main disconnect switch) ........................................ 22
4.7 - Electrical data, optional hydronic module .......................................................................................................................... 23
4.8 - Compressor usage and electrical data table........................................................................................................................ 24
5 - APPLICATION DATA ........................................................................................................................................................... 25
5.1 - Operating limits 61WG.......................................................................................................................................................... 25
5.2 - Operating range 61WG ......................................................................................................................................................... 25
5.3 - Operating limits 30WG.......................................................................................................................................................... 25
5.4 - Operating range 30WG ......................................................................................................................................................... 25
5.5 - Operating limits 30WGA ...................................................................................................................................................... 26
5.6 - Operating range 30WGA ...................................................................................................................................................... 26
5.7 - Minimum chilled water ow ................................................................................................................................................. 26
5.8 - Maximum chilled water ow................................................................................................................................................. 26
5.9 - Variable ow ........................................................................................................................................................................... 26
5.10 - Water ow rates .................................................................................................................................................................... 26
5.11 - Minimum water volume ...................................................................................................................................................... 27
5.12 - Maximum water loop volume (evaporator and condenser side).................................................................................... 27
5.13 - Expansion tank..................................................................................................................................................................... 27
5.14 - Protection against cavitation (option 116)......................................................................................................................... 28
5.15 - Plate heat exchanger pressure drop (includes internal piping)....................................................................................... 28

3
6 - ELECTRICAL CONNECTION............................................................................................................................................ 29
6.1 - Electrical connections, control box 61WG/30WG/ 30WGA ............................................................................................. 29
6.2 - Power supply........................................................................................................................................................................... 29
6.3 - Voltage phase imbalance (%) ............................................................................................................................................... 29
6.4 - Recommended wire sections................................................................................................................................................. 29
6.5 - 24 V user power reserve ........................................................................................................................................................ 31
7 - 30WGA UNIT CONNECTIONS .......................................................................................................................................... 31
7.1 - Recommendations for the installation of liquid chillers with remote condenser............................................................ 31
7.2 - Piping installation and connection........................................................................................................................................ 31
8 - PIPE SIZING WITH REFRIGERANT FOR 30WGA UNITS ....................................................................................... 32
8.1 - General considerations and pipe size limits........................................................................................................................ 32
8.2 - Pipe sizing................................................................................................................................................................................ 32
8.3 - Discharge pipe sizing ............................................................................................................................................................. 32
8.4 - Liquid line sizing .................................................................................................................................................................... 33
9 - WATER CONNECTIONS...................................................................................................................................................... 33
9.1 - Operating precautions ........................................................................................................................................................... 33
9.2 - Water connections .................................................................................................................................................................. 34
9.3 - Frost protection ...................................................................................................................................................................... 35
9.4 - Flow switch (units without hydronic module) .................................................................................................................... 35
10 - NOMINAL WATER FLOW CONTROL WITH FIXED-SPEED PUMP ................................................................... 35
10.1 - General.................................................................................................................................................................................. 35
10.2 - Water fow control procedure ............................................................................................................................................. 35
11 - NOMINAL WATER FLOW CONTROL WITH VARIABLE-SPEED PUMP .......................................................... 36
11.1 - Pump fow/pressure curve..................................................................................................................................................... 36
11.2 - Available external static pressure (variable-speed high-pressure pumps, units with hydronic module ..................... 37
11.3 - Available external static pressure (xed-speed low-pressure pumps, units with hydronic module)......................................38
11.4 - Pump curve (units with hydronic modules)....................................................................................................................... 39
12 - OPERATION OF 61WG UNITS WITH SPECIFIC HEATING CONTROL (OPTION 153) ................................. 39
12.1 - Operating principle .............................................................................................................................................................. 39
12.2 - Auxiliary electronic board (AUX1) - analogue and digital inputs and outputs ........................................................... 39
13 - OPERATION OF 61WG UNITS WITH THE HEATING SYSTEM MANAGER (HSM) ..........................................40
14 - 30WG UNIT OPERATION WITH A DRYCOOLER (OPTION 154) ......................................................................... 41
14.1 - Operating principle .............................................................................................................................................................. 41
14.2 - Auxiliary electronic board (AUX1) - analogue and digital inputs and outputs - to control the drycooler.................... 41
14.3 - Conguration of the number of fan stages and the automatic changeover of the fan stages ..................................... 41
14.4 - Fan stage assignment............................................................................................................................................................ 41
14.5 -
30WG units without evaporator and condenser pump, three-way valve conguration for low outside temperature
application............................................................................................................................................................................. 42
14.6 - Drycooler installation on 30WG units............................................................................................................................... 42
15 - 30WGA UNIT OPERATION WITH A REMOTE AIR-COOLED CONDENSER (OPTION 154)...................... 42
15.1 - Operating principle .............................................................................................................................................................. 42
15.2 - Lead fan................................................................................................................................................................................. 42
15.3 - Auxiliary electronic board (AUX1) - analogue and digital inputs and outputs - to control the remote air-cooled
condenser ............................................................................................................................................................................... 42
15.4 -
Conguration of the number of fan stages and fan type based on the air-cooled condenser model used in the
installation.............................................................................................................................................................................. 42
16 - START-UP............................................................................................................................................................................... 43
16.1 - Preliminary checks ............................................................................................................................................................... 43
16.2 - Actual start-up ...................................................................................................................................................................... 43
16.3 - Refrigerant charge adjustment ........................................................................................................................................... 43
16.4 - Oil charge adjustment.......................................................................................................................................................... 44
16.5 - Operation of two units in master/slave mode (option 58)............................................................................................... 44
16.6 - Parallel or serial connection of two 61WG/30WG/ 30WGA units ................................................................................. 44

4
The illustrations in this document are for illustrative purposes only and not part of any offer for sale or contract.
17 - MAJOR SYSTEM COMPONENTS AND OPERATION DATA................................................................................... 44
17.1 - Compressors........................................................................................................................................................................... 44
17.2 - Lubricant ................................................................................................................................................................................ 45
17.3 - Evaporators and water-cooled condensers......................................................................................................................... 45
17.4 - Electronic expansion valve (EXV) ..................................................................................................................................... 45
17.5 - Refrigerant ............................................................................................................................................................................. 45
17.6 - High-pressure switch and high-pressure sensor................................................................................................................. 46
17.7 - High and low-pressure side safety valves ........................................................................................................................... 46
17.8 - Moisture indicator................................................................................................................................................................. 46
17.9 - Filter drier in the refrigerant circuit.................................................................................................................................... 46
17.10 - Fixed-speed pump ............................................................................................................................................................... 47
17.11 - Variable-speed pump .......................................................................................................................................................... 47
17.12 - Evaporator and condenser pump suction lter ............................................................................................................... 47
17.13 - Connection sleeves.............................................................................................................................................................. 47
17.14 - Option 272: High-temperature water production with glycol solution ........................................................................... 47
17.15 - Outside air temperature sensor ......................................................................................................................................... 47
18 - OPTIONS AND ACCESSORIES........................................................................................................................................ 48
19 - MAINTENANCE................................................................................................................................................................... 49
19.1 - Soldering and welding.......................................................................................................................................................... 49
19.2 - General system maintenance .............................................................................................................................................. 49
19.3 - Refrigerant undercharge...................................................................................................................................................... 49
19.4 - Refrigerant guidelines ......................................................................................................................................................... 49
19.5 - Leak detection ...................................................................................................................................................................... 50
19.6 - Evacuation ............................................................................................................................................................................ 50
19.7 - Recharging liquid refrigerant.............................................................................................................................................. 50
19.8 - Characteristics of R-410A ................................................................................................................................................... 50
19.9 - Electrical maintenance ........................................................................................................................................................ 51
19.10 - Tightening torques for the main electrical connections................................................................................................. 51
19.11 - Tightening torques for the main bolts and screws .......................................................................................................... 51
19.12 - Compressors........................................................................................................................................................................ 51
19.13 - Evaporator and condenser maintenance......................................................................................................................... 51
19.14 - Corrosion check.................................................................................................................................................................. 51
20 - AQUASNAP MAINTENANCE PROGRAM .................................................................................................................. 52
20.1 - Maintenance schedule ......................................................................................................................................................... 52
20.2 - Description of the maintenance operations...................................................................................................................... 52
21 - START-UP CKECKLIST FOR 61WG/30WG/30WGA UNITS (USE FOR JOB FILE) ........................................... 53

5
1 - INTRODUCTION
Prior to the initial start-up of the 61WG/30WG/30WGA
units, the people involved in the on-site installation, start-up,
operation and maintenance of this unit should be thoroughly
familiar with these instructions and the specic project data
for the installation site.
The 61WG/30WG/30WGA units are designed to provide a
very high level of safety during installation, start-up,
operation and maintenance. They will provide safe and
reliable service when operated within their application range.
They are designed for an operating life of 15 years by
assuming a 75% utilisation factor; that is approximately
100,000 operating hours.
This manual provides the necessary information to familiarize
yourself with the control system before performing start-up
procedures. The procedures in this manual are arranged in
the sequence required for machine installation, start-up,
operation and maintenance.
Be sure you understand and follow the procedures and safety
precautions contained in the instructions supplied with the
machine, as well as those listed in this guide.
To nd out, if these products comply with European directives
(machine safety, low voltage, electromagnetic compatibility,
equipment under pressure etc.) check the declarations of
conformity for these products.
1.1 - Installation safety considerations
After the unit has been received, when it is ready to be
installed or reinstalled, and before it is started up, it must be
inspected for damage. Check that the refrigerant circuit(s)
is (are) intact, especially that no components or pipes have
shifted (e.g. following a shock). If in doubt, carry out a leak
tightness check and verify with the manufacturer that the
circuit integrity has not been impaired. If damage is detected
upon receipt, immediately le a claim with the shipping
company.
Do not remove the skid or the packaging until the unit is
in its nal position. These units can be moved with a fork
lift truck, as long as the forks are positioned in the right
place and direction on the unit.
The units can also be lifted with slings, using only the
designated lifting points marked on the unit.
These units are not designed to be lifted from above. Use
slings with the correct capacity,and always follow the lifting
instructions on the certied drawings supplied with the unit.
Safety is only guaranteed, if these instructions are carefully
followed. If this is not the case, there is a risk of material
deterioration and injuries to personnel.
DO NOT COVER ANY PROTECTION DEVICES.
30WGA are supplied without safety valve on the high-pressure
refrigerant circuit and are equipped with automa-tically reset
pressure switches in accordance with EN378.
For unit installation and connection to the remote condenser
it is necessary to:
• Check the applicable air conditioning regulations and
safety standards (e.g.PED and EN378 for the European
Union)
• Determine which accessories (safety valves, fuses etc.)
are required so that these circuits comply with the
applicable regulations and standards.
If shut-off valves are used on the circuit, ensure that these
valves donot shut offthe safetyvalvefor thedifferent containers
that they protect.
The protection devices include the fuse plugs and safety valves
(if used) in the refrigerant or heat transfer medium circuits.
Check if the original protection plugs are still present at the
valve outlets. These plugs are generally made of plastic and
should not be used. If they are still present, please remove
them. Install devices at the valve outlets or drain piping that
prevent the penetration of foreign bodies (dust,building debris,
etc.) and atmospheric agents (water can form rust or ice).
These devices, as well as the drain piping, must not impair
operation and not lead to a pressure drop that is higher than
10% of the control pressure.
Classication and control
In accordance with the Pressure Equipment Directive and
national usage monitoring regulations in the European
Union the protection devices for these machines are classied
asfollows:
Safety
accessory*
Damage limitation accessory**
in case of an external re
Refrigerant side
High-pressure switch x
External relief valve*** x
Rupture disk x
Fuse plug x
Heat transfer uid side
External relief valve**** x x
* Classiedforprotectioninnormalservicesituations.
** Classiedforprotectioninabnormalservicesituations.
*** The instantaneous over-pressure limited to 10% of the operating pressure
doesnotapplytothisabnormalservicesituation.Thecontrolpressurecanbe
higherthantheservicepressure.Inthiscaseeitherthedesigntemperatureor
the high-pressure switch ensures that the service pressure is not exceeded in
normalservicesituations.
**** Theclassicationofthesesafetyvalvesmustbemadebythepersonnelthat
completesthewholehydronicinstallation.
Do not remove these valves and fuses, even if the re risk is
under control for a particular installation. There is no
guarantee thatthe accessoriesare re-installedif theinstallation
is changed or for transport with a gas charge.

6
All factory-installed safety valves are lead-sealed to prevent
any calibration change. If the safety valves are installed on
a reversing valve (change-over), this is equipped with a
safety valve on each of the two outlets. Only one of the two
safety valves is in operation, the other one is isolated. Never
leave the reversing valve in the intermediate position, i.e.
with both ways open (locate the control element in the stop
position).
If a safety stop is removed for checking or replacement
please ensure that there is always an active safety stop on each
of the reversing valves installed in the unit.
The external safety valves must always be connected to drain
pipes for units installed in a closed room. Refer to the
installation regulations, for example those of European
standard EN 378 and EN 13136.
These pipes must be installed in a way that ensures that
people and property are not exposed to refrigerant leaks.
As the uids can be diffused in the air, ensure that the outlet
is far away from any building air intake, or that they are
discharged in a quantity that is appropriate for a suitably
absorbing environment.
Periodic check of the safety valves: See paragraph 1.3 -
“Maintenance safety considerations”.
Provide a drain in the drain pipe, close to each safety valve,
to avoid an accumulation of condensate or rain water.
All precautions concerning handling of refrigerant must be
observed in accordance with local regulations.
Ensure good ventilation, as accumulation of refrigerant in
an enclosed space can displace oxygen and cause asphyxiation
or explosions.
Inhalation of high concentrations of vapour is harmful and
may cause heart irregularities, unconsciousness, or death.
Vapour is heavier than air and reduces the amount of oxygen
available for breathing. These products cause eye and skin
irritation. Decomposition products are hazardous.
1.2 - Equipment and components under pressure
These products incorporate equipment or components under
pressure, manufactured by Carrier or other manufacturers.
We recommend that you consult your appropriate national
trade association or the owner of the equipment or
components under pressure (declaration, re-qualication,
retesting, etc.). The characteristics of this equipment/these
components are given on the nameplate or in the required
documenta-tion, supplied with the products.
These units are intended to be stored and operated in an
environment where the ambient temperature must be not
less than the lowest allowable temperature indicated on the
nameplate.
Do not introduce signicant static or dynamic pressure with
regard to the operating pressures used during operation or
for tests in the refrigerant circuit or in the heat exchange
circuits.
1.3 - Maintenance safety considerations
Carrier recommends the following drafting for a logbook
(the table below should not be considered as reference and
does not involve Carrier responsibility):
Intervention Name of the
commissioning
engineer
Applicable
national
regulations
Verication
Organism
Date Nature (1)
(1) Maintenance,repairs,regularverications(EN378),leakage,etc.
Engineers working on the electric or refrigeration components
must be authorised, trained and fully qualied to do so (e.g.
electricians trained and qualied in accordance with IEC 60364
classication BA4).
All refrigerant circuit repairs must be carried out by a trained
person, fully qualied to work on these units. He must have
been trained and be familiar with the equipment and the
installation. All welding operations must be carried out by
qualied specialists.
Any manipulation (opening or closing) of a shut-off valve
must be carried out by a qualied and authorised engineer.
These procedures must be carried out with the unit shut
down.
Any intervention on the refrigerant circuit, including
changing of drier blocks, is only permitted after the complete
removal of the refrigerant charge. For these units transfer
of the refrigerant charge from the high or low-pressure side
is not possible, nor permitted.
Never use the compressor as a vaccum pump.
During any handling, maintenance and service operations
the engineers working on the unit must be equipped with
safety gloves, glasses, shoes and protective clothing.
Never work on a unit that is still energised.
Never work on any of the electrical components, until the
general power supply to the unit has been cut using the
disconnect switch in the control box.
If any maintenance operations are carried out on the unit,
lock the power supply circuit in the open position ahead of
the machine.
If the work is interrupted, always ensure that all circuits
are still deenergized before resuming the work.
ATTENTION: Even if the compressor motors have been
switched off, the power circuit remains energized, unless the
unit or circuit disconnect switch is open. Refer to the wiring
diagram for further details.
Attach appropriate safety labels.

7
If any intervention is required on the air-cooled condenser
in 30WGA units please refer to the safety instructions
supplied by the condenser manufacturer.
It is recommended to install an indicating device to show
if part of the refrigerant has leaked from the valve. The
presence of oil at the outlet orice is a useful indicator that
refrigerant has leaked. Keep this orice clean to ensure that
any leaks are obvious. The calibration of a valve that has
leaked is generally lower than its original calibration. The
new calibration may affect the operating range. To avoid
nuisance tripping or leaks, replace or re-calibrate the valve.
Operating checks:
IMPORTANT INFORMATION REGARDING THE
REFRIGERANT USED:
• This product contains uorinated greenhouse gas
covered by the Kyoto protocol.
• Refrigerant type: R-410A
• Global Warming Potential (GWP): 1975
ATTENTION:
• Attach the label supplied that shows the refrigerant
used to the side used for topping up and/or recovery.
• On the label clearly indicate the topped up refrigerant
quantity in indelible ink.
• Prevent the release of uorinated gas from the unit.
Ensure that uorinated gas is never released to the
atmosphere during installation, maintenance or
disposal. If a leak of uorinated gas is detected, stop
the leak and repair it as quickly as possible.
• Only a qualied service technician is allowed to access
this product and to correct the fault.
• Any handling of uorinated gas contained in this
product (e.g. moving the product or topping up the gas)
must comply with EC regulation no. 842/2006 about
certain uorinated greenhouse gases and any other
applicable local legislation.
• Contact your local dealer if you have any questions.
• Periodic inspections for refrigerant leaks may be
required depending on European or local legislation.
Please contact your local dealer for more information.
• During the life-time of the system, inspection and tests
must be carried out in accordance with national
regulations.
The information on operating inspections given in annex C
of standard EN378 can be used if no similar criteria exist
in the national regulations.
Protection device checks:
• If no national regulations exist, check the protection
devices on site in accordance with standard EN378:
once a year for the high-pressure switches, every ve
years for external safety valves.
• The detailed description of the high-pressure switch test
method is given in the service manual for the unit.
The company or organisation that conducts a pressure switch
test shall establish and implement a detailed procedure to x:
- Safety measures
- Measuring equipment calibration
- Validating operation of protective devices
- Test protocols
- Recommissioning of the equipment.
Consult Carrier Service for this type of test. Carrier mentions
here only the principle of a test without removing the
pressure switch:
- Verify and and record the set-points of pressure
switches and relief devices (valves and possible
rupture discs)
- Be ready to switch-off the main disconnect switch
of the power supply if the pressure switch does not
trigger (avoid over-pressure or excess gas in case
of valves on the high-pressure side with the recovery
condensers)
- Connect a calibrated pressure gauge (the values
displayed on the user interface may be inaccurate
in an instant reading because of the scanning delay
applied in the control)
- Complete an HP Test as provided by the software
(refer to the Control IOM for details).
At least once a year thoroughly inspect the protection devices
(valves, pressure switches). If the machine operates in a
corrosive environment, inspect the protection devices more
frequently.
Regularly carry out leak tests and immediately repair any
leaks.
1.4 - Repair safety considerations
All installation parts must be maintained by the personnel in
charge, in order to avoid material deterioration and injuries
to people. Faults and leaks must be repaired immediately.
The authorized technician must have the responsibility to
repair the fault immediately. After each repair of the unit,
check the operation of the protection devices and create a
report of the parameter operation at 100%.
Comply with the regulations and recommendations in unit
and HVAC installation safety standards, such as: EN 378, ISO
5149, etc.
If a leak occurs or if the refrigerant becomes polluted (e.g.
by a short circuit in a motor or BPHE frost) remove the
complete charge using a recovery unit and store the
refrigerant in mobile containers.
Repair the leak detected and recharge the circuit with the
total R-410A charge, as indicated on the unit name plate. Do
not top up the refrigerant charge. Only charge liquid
refrigerant R-410A at the liquid line.
Ensure that you are using the correct refrigerant type before
recharging the unit.
Charging any refrigerant other than the original charge type
(R-410A) willimpair machine operation andcan even destroy
the compressors. The compressors operating with this
refrigerant type are lubricated with a synthetic polyol-ester
oil.
Before any intervention on the refrigerant circuit the complete
refrigerant charge needs to be recovered.

8
For 30WGA units with remote condenser the installer must
be clearly note the total refrigerant charge used in the system
(in kg) on the label attached to the 30WGA.
RISK OF EXPLOSION: Never use air or a gas containing
oxygen during leak tests to purge lines or to pressurise a
machine. Pressurised air mixtures or gases containing oxygen
can be the cause of an explosion. Oxygen reacts violently
with oil and grease.
Only use dry nitrogen for leak tests, possibly with an
appropriate tracer gas.
If the recommendations above are not observed, this can
have serious or even fatal consequences and damage the
installation.
Never exceed the specied maximum operating pressures.
Verify the allowable maximum high- and low-side test
pressures by checking the instructions in this manual and
the pressures given on the unit name plate.
Do not unweld or amecut the refrigerant lines or any
refrigerant circuit component until all refrigerant (liquid
and vapour) as well as the oil have been removed from unit.
Traces of vapour should be displaced with dry nitrogen.
Refrigerant in contact with an open ame produces toxic
gases.
The necessary protection equipment must be available, and
appropriate re extinguishers for the system and the
refrigerant type used must be within easy reach.
Do not siphon refrigerant.
The accidental releases of the refrigerant, due to small leaks
or signicant discharges following the rupture of a pipe or
an unexpected release from a safety valve, can cause frostbites
and burns to personnel exposed. Do not ignore such injuries.
Installers, owners and especially service engineers for these
units must:
- Seek medical attention before treating such injuries.
- Have access to a rst-aid kit, especially for treating eye
injuries.
We recommend to apply standard EN 378-3 Annex 3.
Avoid spilling liquid refrigerant on skin or splashing it into
the eyes. Use safety goggles and safety gloves. Wash any
spills from the skin with soap and water. If liquid refrigerant
enters the eyes, immediately and abundantly ush the eyes
with water and consult a doctor.
Never apply an open ame or live steam to a refrigerant
container. Dangerous overpressure can result.If it is necessary
to heat refrigerant, use only warm water.
During refrigerant removal and storage operations follow
applicable regulations. These regulations, permitting
conditioning and recovery of halogenated hydrocarbons
under optimum quality conditions for the products and
optimum safety conditions for people, property and the
environment are described in standard NF E29-795.
Any refrigerant transfer and recovery operations must be
carried out using a transfer unit.3/8” SAE connectors on the
liquid, suction and discharge lines are available for all units
for connection to the transfer station. The units must never
be modied to add refrigerant and oil charging, removal and
purging devices.All these devices are provided with the units.
Please refer to the certied dimensional drawings for the
units.
Do not re-use disposable (non-returnable) cylinders or
attempt to rell them. It is dangerous and illegal. When
cylinders are empty, evacuate the remaining gas pressure,
and move the cylinders to a place designated for their
recovery. Do not incinerate.
Do not attempt to remove refrigerant circuit components
or ttings, while the machine is under pressure or while it
is running. Be sure pressure is at 0 kPa and that the unit
has been shut down and de-energised before removing
components or opening a circuit. If the refrigerant circuit
is open to carry out a repair, all circuit openings must be
plugged, if the repair takes longer than 30 minutes. This
prevents humidity from contaminating the circuit, especially
the oil. If the work is expected to take longer, charge the
circuit with nitrogen.
Do not attempt to repair or recondition any safety devices
when corrosion or build-up of foreign material (rust, dirt,
scale, etc.) is found within the valve body or mechanism. If
necessary, replace the device. Do not install safety valves in
series or backwards.
ATTENTION:No part of the unit must be used as a walk-way,
rack or support. The refrigerant lines can break under the
weight and release refrigerant, causing personal injury.
Do not climb on a machine. Use a platform, or staging to
work at higher levels.
Use mechanical lifting equipment (crane, hoist, winch, etc.)
to lift or move heavy components. For lighter components,
use lifting equipment when there is a risk of slipping or
losing your balance.
Useonly originalreplacement partsforany repairor component
replacement. Consult the list of replacement parts that
corresponds to the specication of the original equipment.
Do not drain water circuits containing industrial brines,
without informing the technical service department at the
installation site or a competent body rst.
Close the entering and leaving water shutoff valves and
purge the unit water circuit,before working on the components
in
stalled on the circuit (screen lter, pump,water ow switch,
etc.).
Periodically inspect all valves, ttings and pipes of the
refrigerant and hydronic circuits to ensure that they do not
show any corrosion or any signs of leaks.
It is recommended to wear ear defenders,when working near
the unit and the unit is in operation.

9
2.2.1 - Moving
See chapter 1.1 - “Installation safety considerations”.
2.2.2 - Placing the unit
Always refer to the chapter “Dimensions and clearances”
to conrm that there is adequate space for all connections
and service operations. For the centre of gravity coordinates,
the position of the unit mounting holes, and the weight
distribution points,refer to the certied dimensional drawing
supplied with the unit.
Typical applications of these units are in refrigeration
systems, and they do not require earthquake resistance.
Earthquake resistance has not been veried.
In case of extra-high units the machine environment must
permit easy access for maintenance operations.
CAUTION: Only use slings at the designated lifting points
which are marked on the unit.
Before siting the unit check that:
• the permitted loading at the site is adequate or that
appropriate strenghtening measures have been taken.
• the unit support points are located at the four lower
corners.
• the positioning at these four points must be horizontal
(level tolerance 1.5 mm/m in both axes)
• if the support structure is sensitive to vibration and/or
noise transmission it it advisable to insert anti-vibration
mounts (elastomeric mounts or springs) between the unit
and the structure. Selection of these devices is based on
thesystemcharacteristics and the comfort level required
and should be made by technical specialists.
• there is adequate space above the unit for air ow and
to ensure access to the components.
• the number of support points is adequate and that they
are in the right places.
• the location is not subject to ooding.
• No material or object that can be affected by condensate
(even a small amount) must be left under the machine
or in the water ow direction.
CAUTION: Before lifting the unit, check that all casing
panels are securely xed in place. Lift and set down the unit
with great care. Tilting and jarring can damage the unit
and impair unit operation.
ATTENTION: Stacked units must not be moved.
If 61WG/30WG/30WGA units are hoisted with rigging, it
is necessary to protect the unit frame (side and rear panels
and front doors) against accidental crushing. Use struts or
lifting beams to spread the slings above the unit. Do not tilt
a unit more than 15°, or 5° for units with the stacking option
(option 273). Always follow the instructions on the handling
notice attached to the unit.
If a unit includes a hydronic module (options 116 or 270),
the hydronic module and pump piping must be installed in
1.5 - Measures, provisions, procedures against
emergencies
When the machine is subjected to heat or re, a device
prevents explosion by releasing the refrigerant (via the relief
valve). This uid can be decomposed into toxic waste when
subjected to ame:
- Stay away from the unit.
- Set up warnings and recommendations for personnel in
charge to stop the re.
- Fire extinguishers appropriate to the system and the
refrigerant type must be easily accessible.
2 - PRELIMINARY CHECKS
2.1 - Check equipment received
• Inspect the unit for damage or missing parts. If damage
is detected, or if shipment is incomplete, immediately
le a claim with the shipping company.
• Compare the name plate data with the order. The name
plate is attached in two places to the unit:
- on one of the unit sides on the outside
- on the control box door on the inside.
• The unit name plate must include the following
information:
- Version number
- Model number
- CE marking
- Serial number
- Year of manufacture and test date
- Refrigerant used and refrigerant class
- Refrigerant charge per circuit
- Containment uid to be used
- PS: Min./max. allowable pressure (high and low
pressure side)
- TS: Min./max.allowable temperature (high and low
pressure side)
- Pressure switch cut-out pressure
- Unit leak test pressure
- Voltage, frequency, number of phases
- Maximum current drawn
- Maximum power input
- Unit net weight
• Conrm that the options ordered for on-site installation
have been supplied, are complete and undamaged.
• Donot keepthe 61WG/30WG/30WGA unitsoutsidewhere
they are exposed to the weather,as the sensitive control
mechanism and the electronic modules may be damaged.
The unit must be checked periodically during its whole
operating life to ensure that no shocks (handling accessories,
tools etc.) have damaged it. If necessary, repair or replace the
damaged parts (see chapter 15 “Maintenance”).
The machine must be installed in a place that is not accessible
to the public or protected against access by non-authorised
persons.
2.2 - Moving and placing the unit

10
a way that does not submit it to any strain. The hydronic
module pipes must be tted so that the pump does not support
the weight of the pipes.
Never push or lever on any of the enclosure panels (panels,
uprights, front access doors) of the unit. Only the base of
the unit frame is designed to withstand such stresses.
Checks before system start-up
Before the start-up of the refrigeration system, the complete
installation, including the refrigeration system must be
verified against the installation drawings, dimensional
drawings, system piping and instrumentation diagrams and
the wiring diagrams.
For these checks national regulations must be followed. If
the national regulation does not specify any details, refer to
standard EN 378 as follows:
External visual installation checks:
• Ensure that the machine is charged with refrigerant,
Verify on the unit nameplate that the ‘uid transported’
is R410A and is not nitrogen.
• Compare the complete installationwith the refrigeration
system and power circuit diagrams.
• Check that all components comply with the design
specications.
• Check that all protection documents and equipment
provided by the manufacturer (dimensional drawings,
P&ID, declarations etc.) to comply with the regulations
are present.
• Verify that the environmental safety and protection and
devices and arrangements provided by the manufacturer
to comply with the regulations are in place.
• Verifythatalldocumentsforpressurecontainers,certicates,
name plates, les, instruction manuals provided by the
manufacturer to comply with the regulationsare present.
• Verify the free passage of access and safety routes.
• Check that ventilation in the plant room is adequate.
• Check that refrigerant detectors are present.
• Verify the instructions and directives to prevent the
deliberate removal of refrigerant gases that are harmful
to the environment.
• Verify the installation of connections.
• Verify thesupports and xingelements (materials,routing
and connection).
• Verify the quality of welds and other joints.
• Check the protection against mechanical damage.
• Check the protection of moving parts.
• Verify the accessibility for maintenance or repair and
to check the piping.
• Verify the status of the valves.
• Verify the quality of the thermal insulation and of the
vapour barriers.
• Ensure that the position of the condensate drain piping
allows draining and that the connections are correct for
the water used.
• Avoid common routing of the customer power wiring
and other machine wiring, especially for longer runs (>
200 mm).

11
3 - DIMENSIONS, CLEARANCES
3.1 - 61WG/30WG 020-045 - standard unit
Legend:
Alldimensionsareinmm.
Evaporator
Condenser
Safety valve
Clearances required for maintenance (see note)
 Controlbox
Water inlet
Water outlet
Power wiring connection
161 237
153 470
160 237
153 470
1058
900
700700
1044 600
625
901
700
2
21
1
4
4
4
4
5
3
3
3.2 - 61WG/30WG 020-045 - unit with top connections (option 274)
901
938
86
105
104
105
143
1044
600
700
900
700
700
700
2
1
4
4
4
4
4
Only for option 70F
NOTE:Non-contractualdrawings.Refertothecertieddimensionaldrawingsavailable
onrequest,whendesigninganinstallation.

12
3.3 - 61WG/30WG 020-045 - unit with evaporator hydronic module (option 116)
3.4 - 61WG/30WG 020-045 - unit with condenser hydronic module (option 270)
3.5 - 61WG/30WG 020-045 - unit with evaporator/condenser hydronic modules (options 116 + 270)
700
900
700
153
161 237
470
868
1044
1058
1463
704
600
625
700
379
3
5
1
2
21
4
3
4
4
4
153
398
153
161
623
1021
142 237
2
2
1
1
398
153 470
398
161
142
623
2
2
1
1
Legend:
Alldimensionsareinmm.
Evaporator
Condenser
Safety valve
Clearances required for maintenance (see note)
 Controlbox
Water inlet
Water outlet
Power wiring connection
Only for option 70F
NOTE: Non-contractual drawings. Refer to the certied
dimensionaldrawingsavailableonrequest,whendesigning
aninstallation.

13
3.6 - 61WG/30WG 020-045 - unit with hydronic module and top connections
(options 116 + 274 or 270 + 274 or 116 + 270 + 274)
900
700700
143
86
237 221
86 167
167
1044
1463
1500
700
700
2
2
1
1
4
4
4
4
4
3.7 - 61WG/30WG 020-045 - stackable unit (option 273)
NOTE:Thewaterandelectricalconnectionsareidenticaltothoseofthestandardunit.
1014
1014
1058 600
1841
900
700700
700
4
4
4
4
Legend:
Alldimensionsareinmm.
Evaporator
Condenser
Safety valve
Clearances required for maintenance (see note)
 Controlbox
Water inlet
Water outlet
Power wiring connection
NOTE:Non-contractualdrawings.Refertothecertieddimensionaldrawingsavailable
onrequest,whendesigninganinstallation.

14
3.8 - 61WG/30WG 050-090 - standard unit
3.9 - 61WG/30WG 050-090 - unit with top connections (option 274)
900
700
700
253 310
201
204
456
450
252 310
451
1474
1489
901
905
880
700
2
21
1
4
4
4
4
53
3
700
900
700
253 142 168 142
80
1474
901
938
880
700
700
2
1
4
4
4
4
4
Legend:
Alldimensionsareinmm.
Evaporator
Condenser
Safety valve
Clearances required for maintenance (see note)
 Controlbox
Water inlet
Water outlet
Power wiring connection
Only for option 70F
NOTE:Non-contractualdrawings.Refertothecertieddimensionaldrawingsavailable
onrequest,whendesigninganinstallation.
4
4
4
4

15
900
700700
657
1021
307
252
558
204
704
1474
1488
1463
905
700
880
253
1
2
1
2
5
3
3
4
4
44
657
1021
559
252
277
204
657
1021
559
252
277
204
282
2
1
1
1
1
2
2
2
3.10 - 61WG/30WG 050-090 - unit with evaporator hydronic module (option 116)
3.11 - 61WG/30WG 050-090 - unit with condenser hydronic module (option 270)
3.12 - 61WG/30WG 050-090 - unit with evaporator/condenser hydronic modules (options 116 + 270)
Legend:
Alldimensionsareinmm.
Evaporator
Condenser
Safety valve
Clearances required for maintenance (see note)
 Controlbox
Water inlet
Water outlet
Power wiring connection
Only for option 70F
NOTE: Non-contractual drawings. Refer to the
certieddimensionaldrawingsavailableonrequest,
whendesigninganinstallation.

16
900
700
700
700
1463
1500
1474
80
172
278 282
80172
700
2
2
1
1
4
4
4
4
4
1841
1014
1489
1014
700
900
700
880
700
4
4
4
4
3.13 - 61WG/30WG 050-090 - unit with hydronic module and top connections
(options 116 + 274 or 270 + 274 - 116 or 270 + 274)
3.14 - 61WG/30WG 050-090 - stackable unit (option 273)
NOTE:Thewaterandelectricalconnectionsareidenticaltothoseofthestandardunit.
Legend:
Alldimensionsareinmm.
Evaporator
Condenser
Safety valve
Clearances required for maintenance (see note)
 Controlbox
Water inlet
Water outlet
Power wiring connection
NOTE:Non-contractualdrawings.Refertothecertieddimensionaldrawingsavailable
onrequest,whendesigninganinstallation.

17
900
700700
700
625
600
1058
1044
901
144
50
203
153 470
397
146
For option 70F only
700
900
700
700
625
600
1463
1058
1044
704
153 868
144
51
203
379
4
4
4
4
1
15
3
7
6
3
146
For option 70F only
3.15 - 30WGA 020-045 - standard unit
3.16 - 30WGA 020-045 - unit with evaporator hydronic module (option 116)
Legend:
Alldimensionsareinmm.
Evaporator
Condenser
Safety valve
Clearances required for maintenance (see note)
 Controlbox
6Refrigerant inlet
7Refrigerant outlet
Water inlet
Water outlet
Power wiring connection
NOTE: Non-contractual drawings. Refer to the
certieddimensionaldrawingsavailableonrequest,
whendesigninganinstallation.

18
900
700
700
700
600
1014
1014
1058
1840
4
4
4
4
900
700
700
700
905
880
204 450
315247
461
192
238 321
901
1488
1474
451
1
1
4
4
4
4
53
7
6
3
For option 70F only
Legend:
Alldimensionsareinmm.
Evaporator
Condenser
Safety valve
Clearances required for maintenance (see note)
 Controlbox
6Refrigerant inlet
7Refrigerant outlet
Water inlet
Water outlet
Power wiring connection
NOTE: Non-contractual drawings. Refer to the
certieddimensionaldrawingsavailableonrequest,
whendesigninganinstallation.
3.17 - 30WGA 020-045 - stackable unit (option 273)
NOTE:Thewaterandelectricalconnectionsareidenticaltothoseofthestandardunit.
3.18 - 30WGA 050-090 - standard unit

19
900
700
700
700
1021
558
238 321
204
192
247
653
HT1488
1474
704
HT1463
880
905
1
1
3
5
7
6
44
4
4
3
700
900
700
700
880
1014
1014
1488
1841
4
4
4
4
Legend:
Alldimensionsareinmm.
Evaporator
Condenser
Safety valve
Clearances required for maintenance (see note)
 Controlbox
6Refrigerant inlet
7Refrigerant outlet
Water inlet
Water outlet
Power wiring connection
NOTE: Non-contractual drawings. Refer to the
certieddimensionaldrawingsavailableonrequest,
whendesigninganinstallation.
3.19 - 30WGA 050-090 - unit with evaporator hydronic module (option 116)
3.20 - 30WGA 050-090 - stackable unit (option 273)
NOTE:Thewaterandelectricalconnectionsareidenticaltothoseofthestandardunit.
For option 70F only

20
4 - PHYSICAL AND ELECTRICAL DATA 61WG/30WG
4.1 - Physical data 61WG
61WG 020 025 030 035 040 045 050 060 070 080 090
Operating weight* kg 191 200 200 207 212 220 386 392 403 413 441
Sound levels**
Sound power level 10-12 W, standard unit dB(A) 67.0 68.5 69.0 69.3 70.0 70.1 71.5 72.0 72.0 73.0 73.4
Compressors Hermeticscroll48.3r/s
Quantity 11111122222
Numberofcapacitysteps 11111122222
Minimum capacity % 100 100 100 100 100 100 50 50 50 50 50
Refrigerant* R-410A
Charge, standard unit kg 3.5 3.5 3.6 3.7 4.0 4.6 7.6 7.8 7.9 8.7 11.5
Charge, unit with option 272 kg 2.7 2.9 2.9 3.0 3.2 3.9 7.2 7.3 7.4 7.6 10.5
Oil 160SZ
Charge per compressor l 3 3.3 3.3 3.3 3.3 3.6 3.3 3.3 3.3 3.3 3.6
Control Pro-Dialog+
Evaporator Direct-expansion plate heat exchanger
Water volume l 3.3 3.6 3.6 4.2 4.6 5.0 8.4 9.2 9.6 10.4 12.5
Water connections Victaulic
Inlet/outlet in 1.5 1.5 1.5 1.5 1.5 1.5 22222
Max.water-sideoperatingpressurewithout
hydronic module
kPa 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000
Condenser Plate heat exchanger
Net water volume l 3.3 3.6 3.6 4.2 4.6 5.0 8.4 9.2 9.6 10.4 12.5
Water connections Victaulic
Inlet/outlet in 1.5 1.5 1.5 1.5 1.5 1.5 22222
Max.water-sideoperatingpressurewithout
hydronic module
kPa 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000
* Weightshownisaguidelineonly.Tondouttheunitrefrigerantcharge,pleaserefertotheunitnameplate
** InaccordancewithISO9614-1,measuredinafreeeld.Thesoundlevelsonlyapplytounitswithoutoptions.Declareddualnumbernoiseemissionvaluesinaccordance
withISO4871(withanassociateduncertaintyof+/-3dB(A)).
4.2 - Physical data 30WG
30WG 020 025 030 035 040 045 050 060 070 080 090
Operating weight* kg 191 200 200 207 212 220 386 392 403 413 441
Sound levels**
Sound power level 10-12 W dB(A) 67.0 68.5 69.0 69.3 70.0 70.1 71.5 72.0 72.0 73.0 73.4
Compressors Hermeticscroll48.3r/s
Quantity 11111122222
Numberofcapacitysteps 11111122222
Minimum capacity % 100 100 100 100 100 100 50 50 50 50 50
Refrigerant* R-410A
Charge kg 3.5 3.5 3.6 3.7 4.0 4.6 7.6 7.8 7.9 8.7 11.5
Oil 160SZ
Charge per compressor l 3 3.3 3.3 3.3 3.3 3.6 3.3 3.3 3.3 3.3 3.6
Control Pro-Dialog+
Evaporator Direct-expansion plate heat exchanger
Water volume l 3.3 3.6 3.6 4.2 4.6 5.0 8.4 9.2 9.6 10.4 12.5
Water connections Victaulic
Inlet/outlet in 1.5 1.5 1.5 1.5 1.5 1.5 22222
Max.water-sideoperatingpressurewithout
hydronic module
kPa 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000
Condenser Plate heat exchanger
Net water volume l 3.3 3.6 3.6 4.2 4.6 5.0 8.4 9.2 9.6 10.4 12.5
Water connections Victaulic
Inlet/outlet in 1.5 1.5 1.5 1.5 1.5 1.5 22222
Max.water-sideoperatingpressurewithout
hydronic module
kPa 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000
* Weightshownisaguidelineonly.Tondouttheunitrefrigerantcharge,pleaserefertotheunitnameplate
** InaccordancewithISO9614-1,measuredinafreeeld.Thesoundlevelsonlyapplytounitswithoutoptions.Declareddualnumbernoiseemissionvaluesinaccordance
withISO4871(withanassociateduncertaintyof+/-3dB(A)).